U.S. patent number 9,938,880 [Application Number 14/237,164] was granted by the patent office on 2018-04-10 for heat exchanger assembly.
This patent grant is currently assigned to Behr GmbH & Co. KG, Mahle International GmbH. The grantee listed for this patent is Veit Bruggesser, Andreas Eilemann, Uwe Grass, Rolf Mueller, Hubert Pomin, Christian Saumweber, Juergen Stehlig. Invention is credited to Veit Bruggesser, Andreas Eilemann, Uwe Grass, Rolf Mueller, Hubert Pomin, Christian Saumweber, Juergen Stehlig.
United States Patent |
9,938,880 |
Bruggesser , et al. |
April 10, 2018 |
Heat exchanger assembly
Abstract
A heat exchanger assembly may include an intercooler and a
housing which encloses said intercooler. The housing may be part of
a charge air line. The housing may include a charge air inlet, a
charge air outlet and an opening through which the intercooler can
be inserted into the housing from one side. The housing may also
include a recess on the side opposite the opening, into which
recess the intercooler engages. The heat exchanger assembly may
include an elastic seal arranged in the region of the recess
between the intercooler and the housing. The seal may be configured
to at least one of bridge the deformation of the housing occurring
during pressure pulsations, bridge relative movements between the
intercooler and the housing, and tightly connect the intercooler to
the housing in all operating states preventing an undesirable
bypass flow.
Inventors: |
Bruggesser; Veit
(Hildrezhausen, DE), Eilemann; Andreas
(Erdmannhausen, DE), Grass; Uwe (Stuttgart,
DE), Mueller; Rolf (Steinheim/Murr, DE),
Pomin; Hubert (Sindelfingen, DE), Saumweber;
Christian (Stuttgart, DE), Stehlig; Juergen
(Neckartenzlingen, DE) |
Applicant: |
Name |
City |
State |
Country |
Type |
Bruggesser; Veit
Eilemann; Andreas
Grass; Uwe
Mueller; Rolf
Pomin; Hubert
Saumweber; Christian
Stehlig; Juergen |
Hildrezhausen
Erdmannhausen
Stuttgart
Steinheim/Murr
Sindelfingen
Stuttgart
Neckartenzlingen |
N/A
N/A
N/A
N/A
N/A
N/A
N/A |
DE
DE
DE
DE
DE
DE
DE |
|
|
Assignee: |
Mahle International GmbH
(DE)
Behr GmbH & Co. KG (DE)
|
Family
ID: |
46601803 |
Appl.
No.: |
14/237,164 |
Filed: |
July 26, 2012 |
PCT
Filed: |
July 26, 2012 |
PCT No.: |
PCT/EP2012/064739 |
371(c)(1),(2),(4) Date: |
May 19, 2014 |
PCT
Pub. No.: |
WO2013/020826 |
PCT
Pub. Date: |
February 14, 2013 |
Prior Publication Data
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|
|
|
Document
Identifier |
Publication Date |
|
US 20140246186 A1 |
Sep 4, 2014 |
|
Foreign Application Priority Data
|
|
|
|
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Aug 5, 2011 [DE] |
|
|
10 2011 080 474 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28F
9/0075 (20130101); F28D 9/0031 (20130101); F02B
29/0462 (20130101); F28F 9/005 (20130101); F01P
1/06 (20130101); F02M 35/10236 (20130101); Y02T
10/146 (20130101); Y02T 10/12 (20130101) |
Current International
Class: |
F28F
9/02 (20060101); F28F 9/00 (20060101); F28F
9/007 (20060101); F28D 9/00 (20060101); F01P
1/06 (20060101); F02B 29/04 (20060101); F02M
35/10 (20060101) |
Field of
Search: |
;165/168,70,71,283,152,153,176 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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4313505 |
|
Oct 1994 |
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DE |
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102005012761 |
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Sep 2006 |
|
DE |
|
102007030464 |
|
Jan 2009 |
|
DE |
|
102008061759 |
|
Jun 2010 |
|
DE |
|
102010011372 |
|
Oct 2010 |
|
DE |
|
102009025292 |
|
Jan 2011 |
|
DE |
|
102009038592 |
|
Mar 2011 |
|
DE |
|
102009043264 |
|
Mar 2011 |
|
DE |
|
2014892 |
|
Jan 2009 |
|
EP |
|
2886390 |
|
Dec 2006 |
|
FR |
|
WO 02/18758 |
|
Mar 2002 |
|
WO |
|
WO-02/18758 |
|
Mar 2002 |
|
WO |
|
Other References
English abstract for DE102005012761. cited by applicant .
English abstract for DE4313505. cited by applicant .
English abstract for FR2886390. cited by applicant .
European Opposition dated Jan. 24, 2017 related to corresponding
European Application No. 12 741 317.7. cited by applicant.
|
Primary Examiner: Raymond; Keith
Assistant Examiner: Hincapie Serna; Gustavo
Attorney, Agent or Firm: Fishman Stewart PLLC
Claims
The invention claimed is:
1. A heat exchanger assembly, comprising: an intercooler; a housing
enclosing the intercooler, the housing being part of a charge air
line, the housing including a charge air inlet, a charge air outlet
and an opening through which the intercooler can be inserted into
the housing from one side, wherein the intercooler is arranged in
an air flow path between the charge air inlet and the charge air
outlet; the housing further including a wall defining a recess
disposed on the side opposite to the opening, and the intercooler
is arranged engaging into the recess; an elastic seal disposed in
the region of the recess between the intercooler and the housing to
facilitate preventing a bypass flow in the region of the recess,
wherein the seal is configured to at least one of bridge the
deformation of the housing occurring during pressure pulsations,
bridge relative movements between the intercooler and the housing,
and sealingly connect the intercooler to the housing in all
operating states; wherein an enclosed space defining a volume
sealed off from the air flow path is disposed in the region of the
recess between the intercooler and the housing, the enclosed space
defined by a bottom of the intercooler and the wall of the housing
defining the recess, wherein the seal fluidly seals the volume of
the enclosed space from the air flow path; an aperture disposed in
the wall of the housing defining the recess, wherein the volume of
the enclosed space is in fluid communication with an external
environment via the aperture such that a leaking air flow
penetrating the enclosed space into the volume is communicated to
the external environment; and wherein the seal is an injection
molded material fixedly bonded to the housing and engaged against
by the intercooler such that the seal securely connects the
intercooler to the housing.
2. The heat exchanger assembly according to claim 1, wherein the
seal is at least one of an O-ring seal, a labyrinth seal, and a
sealing lip.
3. The heat exchanger assembly according to claim 1, wherein the
housing is composed of plastic.
4. The heat exchanger assembly according to claim 1, wherein the
intercooler is at least one of air-cooled and coolant-cooled.
5. The heat exchanger assembly according to claim 1, wherein the
intercooler has a flange connecting the intercooler to the housing
in the region of the opening.
6. The heat exchanger assembly according to claim 1, wherein the
housing is part of an intake module of an internal combustion
engine.
7. The heat exchanger assembly according to claim 1, wherein the
seal is a radial seal.
8. The heat exchanger assembly according to claim 1, further
comprising a flange plate disposed at the bottom of the intercooler
in the region of the recess, the flange plate provided with a bent
edge engaging against the seal to facilitate preventing the bypass
flow.
9. The heat exchanger assembly according to claim 4, wherein the
coolant is water.
10. The heat exchanger assembly according to claim 1, wherein the
intercooler contains a heat transfer region including a plurality
of heat transfer elements, the intercooler further including a
coolant inlet nozzle and a coolant outlet nozzle for a coolant, and
wherein the heat transfer region of the intercooler is arranged in
a coolant flow path between the coolant inlet nozzle and the
coolant outlet nozzle.
11. The heat exchanger assembly according to claim 10, wherein the
intercooler has a flange plate disposed at the bottom of the
intercooler in the region of the recess, the flange plate having a
bent edge resting against the seal, wherein the seal is disposed
between the bent edge of the flange plate and the wall of the
housing defining the recess.
12. The heat exchanger assembly according to claim 10, wherein the
plurality of heat transfer elements includes cooling fins.
13. The heat exchanger assembly according to claim 1, further
comprising a pressure release valve coupled to the housing
configured to open in response to a pressure exceeding a predefined
threshold.
14. An intake module of an internal combustion engine, comprising:
a housing and an intercooler arranged in the housing; the housing
including a charge air inlet, a charge air outlet and an opening
via which the intercooler is insertable into the housing, wherein
the intercooler is arranged in an air flow path between the charge
air inlet and the charge air outlet; the housing further including
a wall defining a recess on a side opposite the opening, wherein
the intercooler engages into the recess and provides an enclosed
space in a region of the recess having a volume sealed off from the
air flow path, and wherein the enclosed space is defined by a
bottom of the intercooler and the wall of the housing defining the
recess; an elastic seal arranged in the region of the recess
between the intercooler and the housing, wherein the seal is
configured to at least one of compensate for a deformation of the
housing during a pressure pulsation, compensate for relative
movements between the intercooler and the housing, and sealingly
connect the intercooler to the housing to facilitate preventing a
bypass air flow; a flange plate disposed at the bottom of the
intercooler in the region of the recess, the flange plate having a
bent edge engaging against the seal such that the seal is disposed
between the bent edge of the flange plate and the housing; an
aperture disposed in the wall of the housing defining the recess,
wherein the volume of the enclosed space communicates with an
external environment via the aperture to discharge a leaking air
flow penetrating into the volume from the air flow path; and
wherein the seal is an injection molded material fixedly bonded to
the housing and engaged against by the bent edge of the flange
plate such that the intercooler is securely connected to the
housing.
15. The intake module according to claim 14, wherein the housing is
part of a charge air line.
16. The intake module according to claim 14, further comprising a
pressure release valve coupled to the housing configured to open in
response to a pressure exceeding a predefined threshold.
17. The intake module according to claim 14, wherein the flange
plate extends along the intercooler in the region of the recess
between the bent edge engaging against the seal.
18. The heat exchanger assembly according to claim 8, wherein the
flange plate extends along the intercooler in the region of the
recess between the bent edge engaging against the seal.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to German Patent Application
Number 10 2011 080 474.9, filed Aug. 5, 2011, and International
Patent Application No. PCT/EP2012/064739, filed Jul. 26, 2012, both
of which are hereby incorporated by reference in their
entirety.
TECHNICAL FIELD
The present invention relates to a heat exchanger assembly having
an intercooler and housing which encloses said intercooler,
according to the preamble of the claim 1.
BACKGROUND
From EP 2 014 892 B1, a generic heat exchanger assembly is known
that has an intercooler and a housing enclosing the same, wherein
the housing is part of a charge air line. Moreover, the housing has
a charge air inlet, a charge air outlet and an opening through
which the intercooler can be inserted into the housing from one
side. On the housing side opposite said opening, the housing has a
recess that receives the intercooler at least partially. The
housing is preferably formed from plastic.
The disadvantage of the known prior art is that due to pressure
pulsations in the charge air line, deformations of the housing can
occur, which deformations are severe to such an extent that a gap
is released between the intercooler and the housing, resulting in
an undesirable bypass flow bypassing the intercooler. Through this,
the cooling capacity of the intercooler is reduced.
SUMMARY
The present invention is therefore concerned with the problem of
providing for a heat exchanger assembly an improved or at least
alternative embodiment which is in particular characterized by a
high cooling capacity in all operating states.
This problem is solved according to the invention by the subject
matter of the independent claim 1. Advantageous embodiments are
subject matter of the dependent claims.
The present invention is based on the general idea of elastically
sealing an intercooler protruding into the housing, which housing
is part of a charge air line or a suction tube, with respect to the
housing in such a manner that the pressure pulsations occurring in
the charge air line, which can result in deformations and in
particular in inflation of the housing, do not release bypass paths
which enable undesirable bypassing of the intercooler. In a known
manner, the housing has a charge air inlet, a charge air outlet and
an opening through which the intercooler is inserted from one side.
On the housing side opposite said opening, a recess is provided in
which the intercooler engages. According to the invention, an
elastic seal is arranged in the region of the recess between the
intercooler and the housing, which seal, as mentioned above, is
designed in such a manner that it bridges the deformations of the
housing occurring during the pressure pulsations and thus bridges
the relative movements between the intercooler and the housing and
tightly connects the intercooler to the housing in all operating
states, and thus prevents an undesirable bypass flow and also an
associated reduction of the cooling capacity. Due to the elastic
sealing between the intercooler on the one hand and the housing on
the other, a reliable flow through the intercooler and thus a
sufficient cooling capacity is ensured that is independent of the
operating state of the internal combustion engine connected to the
housing and is also independent of the occurring pressure
pulsations.
In an advantageous refinement of the solution according to the
invention, the seal is designed as an O-ring seal, as a labyrinth
seal or a sealing lip. This enumeration already indicates how
versatile the seal according to the invention can be, wherein it is
only of importance to seal the intercooler with respect to the
housing in all operating states and thereby to avoid the
undesirable bypass flow which reduces the cooling capacity.
In a further advantageous embodiment, the seal is firmly bonded to
the housing, in particular adhesively bonded, vulcanized or
injection molded to the housing. Such injection molding of the seal
onto the housing simplifies, on the one hand, the production and
manufacture of the seal according to the invention and, on the
other, it ensures a secure mount of the seal at least with regard
to the housing. Moreover, in the case of such a seal that is
connected in a firmly bonded manner, in particular by injection
molding, an additional assembly step, namely inserting a separate
seal, can be eliminated so that assembly can be simplified and,
accordingly, production costs can be reduced. Here, the seal can be
formed from a separate material with suitable sealing properties,
or can consist of the same material as the housing. Here, the seal
can be manufactured as a molded seal or a sealing lip together with
the housing during the production of the same.
In one configuration according to the invention, the housing has an
aperture in the region of the recess. Through this aperture, the
volume formed between the intercooler and the housing can
communicate with the environment. This is in particular
advantageous if between the seal and the housing a leaking air flow
penetrates into this volume. This leaking air flow could cause that
the intercooler is pressed out of the recess and a larger gap is
formed, or that parts deform. This leaking air flow can escape
through this opening into the environment without causing damage to
the heat exchanger module, in particular to the intercooler or the
housing. In a refinement of the device according to the invention,
the opening is implemented such that in the region of the recess,
the wall of the housing is completely cut through, and only a
sealing edge for mounting the seal is provided. Thus, a part of the
intercooler would form a part of the housing.
Further important features and advantages of the invention arise
from the sub-claims, from the drawings, and from the associated
description of the figures based on the drawings.
It is to be understood that the above-mentioned features and the
features still to be explained hereinafter are usable not only in
the respective mentioned combination, but also in other
combinations or alone, without departing from the context of the
present invention.
Preferred exemplary embodiments of the invention are illustrated in
the drawings and are explained in more detail in the following
description, wherein identical reference numbers refer to identical
or similar or functionally identical components.
BRIEF DESCRIPTION OF THE DRAWINGS
In the figures, schematically:
FIG. 1 shows a sectional view through a heat exchanger assembly
according to the invention,
FIG. 2a shows a sectional view through another possible embodiment
of the heat exchanger assembly, with the end closed,
FIG. 2b shows a sectional view through another possible embodiment
of the heat exchanger assembly, with the end open,
FIG. 3 shows a sectional view through the sectional plane A-A.
DETAILED DESCRIPTION
According to FIG. 1, the heat exchanger assembly 1 according to the
invention has an intercooler 2 and housing 3 that encloses said
intercooler and can be part of a charge air line. The housing 3
also has a charge air inlet 4, a charge air outlet 5 and an opening
6 through which the intercooler 2 can be inserted into the housing
3 from one side. Opposite the opening 6, the housing 3 has a recess
7 in which the intercooler 2 engages. During pressure pulsations
taking place in the housing 3, it can occur that the housing is
inflated and thereby deforms outwardly, which would cause an
undesirable bypass flow in the region of the recess 7 that bypasses
the intercooler 2. For this reason, an elastic seal 8 is arranged
according to the invention in the region of the recess 7 between
the intercooler 2 and the housing 3, which seal is designed such
that it bridges the deformations of the housing 3 occurring during
pressure pulsations and thus bridges the relative movements between
the intercooler 2 and the housing 3 and tightly connects the
intercooler 2 to the housing 3 in all operating states, and thereby
prevents the undesirable bypass flow.
The seal 8 according to the invention can be designed, for example,
as an O-ring seal, as a labyrinth seal or as a sealing lip, wherein
this enumeration already indicates that the configuration of the
seal 8 is almost freely selectable, provided that the seal is able
to compensate or bridge the relative movements occurring during the
operation of the heat exchanger assembly 1 between the intercooler
2 on the one hand, and the housing 3 on the other. The housing 3 is
preferably formed from plastic, in particular if it is part of an
intake module of an internal combustion engine. In contrast, the
intercooler 2 usually is formed at least partially from metal, in
particular in the region of heat transfer, thus, for example, in
the region of cooling fins 9. Here, the intercooler 2 can be
fluid-cooled, thus, for example, air-cooled or coolant-cooled, in
particular water-cooled, and for this purpose, it can comprise a
coolant inlet nozzle 10 and a coolant outlet nozzle 11.
When viewing FIG. 1, it can be seen that the intercooler 2 has a
flange 12 via which the intercooler is tightly connected to the
housing 3 in the region of the opening 6. However, in the region of
the recess 7, the intercooler 2 has a flange plate 13 with a bent
edge which rests tightly against the seal 8.
In order to simplify the production process, the seal 8, for
example, can be injection molded onto the housing 3 or onto the
intercooler 2, wherein in particular injection molding onto the
housing 3 enables simple assembly of the intercooler 2. As is
apparent from FIG. 1, the seal 8 is designed in this case as a
radial seal.
In the region of the housing 3, an overpressure/low-pressure valve
14 can generally also be provided, which in particular releases
overpressure to the environment upon exceeding a predefined limit
value. It is also conceivable here that instead of the
overpressure/low-pressure valve 14, an equalizing opening is
provided which reduces peak pressures.
Due to the seal 8 provided according to the invention it is
therefore possible to avoid in all operating states an bypass flow
that is undesirable and reduces the cooling capacity of the
intercooler 2, this means in particular also during pressure
pulsations which could cause inflation of the housing 3. In
addition, such a seal 8 can be produced in a comparatively
cost-effective manner.
In one configuration according to the invention, the housing 3 has
an aperture 15 in the region of the recess 7. Through this aperture
15, the volume formed between the intercooler 2 and the housing 3
can correspond with the environment 16. This is particularly
advantageous if between the seal 8 and the housing 2, a leaking air
flow penetrates into said volume. The leaking air flow could result
in that the intercooler 2 is pressed out of the recess 7 and a
larger gap is formed or parts deform. This leaking air can escape
through the aperture 15 into the environment 16 without causing
damage to the heat exchanger assembly 1, in particular to the
intercooler 2 or the housing 3.
FIGS. 2a, b show another heat exchanger assembly 1 which likewise
has an intercooler 2 that can be inserted into a housing 3. The
flow direction of the charge air to be cooled within the housing 3
runs perpendicular to the image plane. In the present case, the
intercooler 2 is inserted into the housing 3 from the left side
until the seals 8, 8' seal the intercooler 2 with respect to the
housing 3. The housing 3 of the heat exchanger assembly 1 is
connected according to FIG. 2a in the region of a deflection tank
19, but it can also be open, as illustrated according to FIG.
2a.
The intercooler 2 is constructed as follows: On the left side, it
has a coolant inlet nozzle 10 and a coolant outlet nozzle 11, which
are arranged one behind the other in the drawing. Connected
thereto, a first coolant tank 17 is provided via which the coolant
flows into the actual intercooler 2 or the fins 9, respectively. On
the right side, the deflection tank 19 is connected, which effects
a deflection of the coolant flow by 180.degree.. The region of the
fins 18 is square in cross-section, whereas the intercooler 2 has a
round cross-section in the region of the seals 8 and 8'. The seals
8, 8' thus can be designed as O-ring seals. A diagonal of the
square fin region 9 is at a maximum as large as an outer diameter
of the seal 8'. Also, a cross-sectional shape of the seals 8, 8'
can be formed such that under pressure, they rest against the
housing 3, in particular with sealing lips which are not shown
here. Suitable as material for such seals 8, 8' are in particular
two-component materials.
The installation of the intercooler 2 is carried out as follows:
First, the intercooler 2 is inserted into the housing 3, namely far
enough that the seal 8' abuts axially against an edge 20 of the
housing 3 and the seal 8 abuts against an edge 20'. In this state,
the flange 12 or the flange plate 13 rests against the housing 3.
The seal 8 has a larger diameter than the seal 8'. Subsequently,
the intercooler 2 is turned about its longitudinal axis 21, for
example by 10-15.degree., as a result of which the fins 9 turn as
well, and in this turned state, they occupy a previously upper
space and lower space 22, 22' so that no undesirable bypass flow
bypassing the fins 9 can occur here. The illustration in FIG. 2b
and in FIG. 3 (dashed line) shows the intercooler 2 prior to
turning.
In the sectional view in FIG. 3 it can be seen that the initially
diagonally inserted intercooler 2 is turned clockwise by ca.
15-20.degree. for final installation. In this end position,
illustrated by a solid line, a bypass flow through the spaces 22,
22' is therefore no longer possible so that the charge air flow is
guided exclusively through the intercooler 2. In contrast to the
heat exchanger assemblies known up to now, the intercooler 2 is
therefore no longer only inserted, but is subsequently turned from
the installation position (diagonal) into the end position. Hereby,
a bayonet catch-type plug-and-turn connection can be implemented.
After reaching the end position, the flange 12 can snap in, for
example.
The seals 8, 8' are appropriately designed for plastic and in
addition to the sealing function, they also enable a bearing
function when turning the intercooler 2 for reaching the end
position. The seals 8, 8' seal in particular the critical points A,
B, C and D.
For fixing the intercooler 2 in the housing 3, advantageously, a
clip lock or a bayonet catch can be provided. In particular the
latter significantly facilitates assembly and disassembly of the
intercooler 2 and secures the same at the same time in the
installed state. Of course, screwing or welding the intercooler 2
to the housing 3 is also conceivable. With the design according to
the invention of the intercooler 2, in particular the forces acting
on the intercooler 2, in particular flange forces, are reduced
since by means of the two seals 8, 8', floating mounting can be
achieved. The seals 8, 8' act in the radial direction and also in
the axial direction.
The intercooler 2 is preferably made from light metal, in
particular from aluminum.
* * * * *